Optimise biogas production

Achieving maximum efficiency in biogas production requires perfect integration between liquid and solid feedstocks, along with the removal of contaminants. Wangen Pumps' BIO-ROXX mixing module is designed to accelerate the fermentation process and boost biogas output by blending solid and liquid materials to create the ideal inoculum. The system minimises air intake while effectively eliminating solid bodies like stones, optimising both the quality and quantity of biogas production.

Positioned downstream of the dry substrate hopper and liquid feeder, just before the fermenter, the BIO-ROXX module ensures a uniform substrate mixture that enhances decomposition rates in Anaerobic Digestion (AD) plants. This leads to faster gas production, making it especially beneficial for plants with capacities of 1-10 MW, where high gas purity is crucial for meeting grid standards.

Maximising Biogas Efficiency

The BIO-ROXX features a sealed mixing chamber with a discharge pump positioned below the fill line to prevent air intrusion that could disrupt the anaerobic digestion process. Inside, its unique arrangement of mixing rods and blades ensures that organic solids are thoroughly suspended and diluted, providing an ideal environment for anaerobic bacteria to convert organic matter into biogas. This process not only boosts the efficiency of the fermenter by reducing viscosity, but it also prevents the formation of a "float" layer—a crust of fibrous solids that can impede the digestion process. By avoiding this issue, the BIO-ROXX maintains consistent gas production, reduces energy consumption, and minimises the risk of damage to stirrer paddles.

Efficient Contaminant Removal

Contaminants like stones, glass, wood, or metal fragments can significantly reduce the efficiency of a biogas plant. They can accumulate in the fermenter, occupying valuable tank space, and may even cause blockages or damage to equipment such as pipelines and pumps.

The BIO-ROXX ensures that organic substrates with a dry matter content of up to 18% flow through the system at more than 85 m³/h (22,484 gallons per hour). The system’s design facilitates the settling of solid contaminants at the bottom of the mixing chamber, where they are trapped and safely removed, preventing any harmful material from entering the fermenter. This reduces the need for frequent tank maintenance or repairs.

Versatile and Adaptable Technology

Wangen Pumps’ BIO-ROXX is highly versatile, capable of processing a broad range of organic materials, including straw, maize stalks, whole-crop silage, manure, and food waste. For substrates containing long fibrous materials (over 30 cm), the BIO-ROXX can be paired with additional equipment such as hammer mills, extruders, or macerators to further improve operational efficiency.

Engineered for both mesophilic and thermophilic Anaerobic Digestion processes, the BIO-ROXX is built to withstand tough conditions, including high temperatures. It can handle up to 18% dry matter content and provides reliable performance in challenging environments. Its adaptability, robust steel construction, and capacity to process an expanding range of feedstocks make it an invaluable asset for biogas plants globally, offering a forward-thinking solution to meet the growing demands of the biogas industry.